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Indian Chemical Council (ICC), Gu- (Leverkusen, Germany), stressed that and even China and Saudi Arabia on  Provision of dump tank for contain-
jarat, and Chairman, Sustainability the safe use of phosgene depends on this aspect. USA China India Korea Argentina Hungary ments; and
Committee, ICC, expressed pleasure a multi-layer safety concept spanning  Connection of all equipment to
at the progress made by the event, now primary (prevention) and secondary Referring to some industry best scrubbing system to combat emer-
in its 11th edition. “Its’ steady growth (mitigation) with one goal – no acci- practices, he noted that the global use gency situation, with dedicated
year-on-year means it has a resilience dents involving phosgene. of medical badges to detect phosgene emergency scrubber with UPS
and relevance that bodes well for its exposure levels is now well estab- 6 1 power backup for all essential ope-
future,” he observed. lished. “98% of producers and users rations.
worldwide use phosgene dosimeter
Mr. Prakash Raman, Managing badges. These companies produce, use 2 “Phosgene badge is mandatory
Director, Silox India Pvt. Ltd., who was and process >99% of all the phosgene 6 in phosgene operating areas to detect
the Chief Guest, dwelt on the safety in the world.” 5 workplace exposure, if any. We are
and the sustainability challenges for 4 planning to make it mandatory across
the broader Indian chemical industry, In India, only two companies – Atul 1 1 1 1 other plants as well,” Mr. Iyer noted.
which are unique since about two-third and Paushak – are known to use these
of the industry participants are SMEs. badges (as of 2021). 2007-2008 2009-2010 2011-2012 2013-2014 2015-2016 2017-2018 2019-2020 2021-2022 Engineering and operational best
“The chemical industry in Gujarat is Fig. 1: Fatalities in the Global Phosgene Industry practices
expected to grow multi-fold over the Mr. Drees also stressed the relevance Dr. Christian Lange, Plant & Process
next few days, but the fundamental Mr. Stefan Drees of Phosgene Exposure Identifi cation hydrogen obtained by the electrolysis Recent developments in phosgene Safety, Covestro Deutschland AG,
challenge is to ensure sustainable and The global industry’s track record Cards, provided by fi rst responders of water; and recycle of HCl or NaCl safety Leverkusen (Germany), highlighted some
safe growth.” on phosgene-related fatalities has seen at the site, and colour-coded based on co-produced. Mr. Ramakrishnan Iyer, Head, of the incidences of phosgene release
signifi cant improvement in recent times badge reading. “A person exposed to Manufacturing, Paushak Ltd., high- during plant start-up and maintenance
with none reported between Septem- phosgene is out of the ordinary and there In conclusion, Mr. Drees emphasised lighted some recent developments activities.
ber 2018 till the end of 2021. But this is not enough experience with treating the need to keep focus on the paramount with respect to phosgene safety at its
three-year trend was broken on January them; these cards provide high level goal, viz., zero incidents. “Trust takes site in Panelav, Panchamahal, Gujarat. “Operators must be aware that during
25, 2022, when an exposure to liquid suggestions for immediate therapy. years to establish and can easily be lost Besides captively consuming phos- start-up phase phosgene can enter parts
phosgene led to one fatality in a fi ne A QR code on them also guides to a by just one major incident. Risk evalu- gene to make chloroformates, Paushak of the plant where it is normally not
chemical production unit in Hungary. website for more information.” A roll- ation by capital investors can change also supplies it to UPL’s adjacent site expected in steady state conditions,” he
The situation was aggravated as the out of this initiative is planned for the easily upon an incident. Phosgene still via pipeline. cautioned.
worker did not wear personal protective end of this year. carries the stigma of a poisonous gas
equipment or a phosgene badge, and, in used in warfare.” The measures undertaken include Dr. Lange also stressed the impor-
a serious deviation of established medi- He pointed to the growing trend to converting shed-type plants for phos- tance of fl ange management for reduc-
cal treatment practices, sent home as he use triphosgene – a solid – as an alter- Medical intervention gene reactors, CO generation, chlorine tion in gas leakages. In his experience,
Mr. Prakash Raman
showed no immediate symptoms due to native to phosgene in the manufacture Dr. Marc Vosskaemper, Global storage and handling to well-ventilated fl anges are best avoided in phosgene
Mr. Raman noted that while many the exposure. of fi ne chemicals in multi-purpose faci- Head, Emergency Response & Medical closed-loop plant; and installation of service to the extent possible, and
SMEs see safety as an expensive exer- lities, which could also pose safety Affairs, Covestro, Germany, observed automated DCS-operated facility for threaded connections are only accepted
cise, “the cost of non-compliance to Nevertheless, he felt the industry issues; and to the development of non- that between 2010 and 2021, between phosgene generation, chlorine storage in/for analyser systems. While normally
safety is even higher.” Safety, he added, has made signifi cant progress in safe phosgene routes, particularly for some 40-70 phosgene exposures were re- and handling (with emergency scrubber smooth fl anges are used, sometimes
“is also about changing social behavi- and sustainable use of phosgene in smaller volume chemicals. “The impor- ported yearly, with many cases going facility) and CO generation sections. tongue-and-groove fl anges are permitted,
our, which is hard to do.” large-scale production. At Covestro, tance of non-phosgene based processes unreported. A vast majority (79%) of and, generally, metallic/graphite gaskets
the number of recorded emissions has to substitute phosgene in large-volume these cases were production related Enhanced safety features at the are preferred.
He urged the chemical industry to declined signifi cantly since 1998, but productions will remain low for di- (57% minor, 40% moderate, 3% major plant include:
be open when it comes to sharing know- has been stable since 2014 even as isocyanates, which account for 80% or death).  Jacketed phosgene pipeline with While torquing is normally done by
ledge, especially in matters related consumption quadrupled in the time of global phosgene volume,” he added. minimum fl ange joints to reduce contractors, Dr. Lange recommended
to safety, and to focus on effectively frame (1998-2022). “The emissions are While there are some debates on the potential of joints failures with 100% that it be checked by company person-
transmitting the learnings on safety to levelling out – but are not close to zero The future could see, in his view, effectiveness of steroids as a useful in- radiography for all weld joints; nel, and tightness tests conducted prior
the shop-fl oor. per year,” Mr. Drees stated. innovative and sustainable routes to tervention, there is unanimity that stan-  Selection of suitable material of con- to taking any equipment into operation.
make phosgene raw materials includ- dardized and trained medical treatment struction for equipment in chlorofor-
Multi-layer safety concept India, he noted in a chart, is pro- ing carbon dioxide (CO ) based pro- on site and, if needed, in hospital as mates plant; Process Safety Incident (PSI)
2
Mr. Stefan Drees, Head – Global gressing on implementing safety stan- duction of carbon monoxide (CO) us- essential for the best outcome possible  Closed-loop sampling and product- Classifi cation

Phosgene Steering Group, Covestro dards, but still lags the developed world ing renewable energy sources, using and to avoid major or death cases. fi lling; Mr. Barkath Udmman, Vice President,

174 Chemical Weekly September 19, 2023 Chemical Weekly September 19, 2023 175

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